Safety electrical outlet and switch system

ABSTRACT

An electrical box is mounted on a wall stud, and a wiring panel is installed within the electrical box so as to partition the interior of the electrical box into a user inaccessible wiring compartment and a user accessible module compartment. A protective cover is attached to the wiring panel so as to protect the wiring panel during a makeup phase of wall panel installation and painting. After the makeup phase, the protective cover is removed from the wiring panel and a module having a user operable electrical function is mounted to the wiring panel within the user accessible module compartment.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/354,264 filed Feb. 14, 2006, which is a continuation of U.S. patentapplication Ser. No. 10/685,294 filed Oct. 14, 2003, now abandoned,which is a continuation of U.S. patent application Ser. No. 10/023,393filed Dec. 17, 2001, now abandoned, which is a divisional of U.S. patentapplication Ser. No. 09/553,425 filed Apr. 19, 2000, now U.S. Pat. No.6,341,981, which relates to and claims the benefit of U.S. ProvisionalPatent Application No. 60/174,521 entitled “SAFETY ELECTRICAL WIRINGASSEMBLY,” filed Jan. 5, 2000. All of the above-referenced patentapplications and patents are hereby incorporated by reference herein intheir entirety.

BACKGROUND OF THE INVENTION

Installation of a standard AC electrical system in a new residence orcommercial site occurs in three phases, corresponding to the buildingconstruction. The rough phase corresponds to rough framing of thebuilding, prior to attachment of wall panels to the frame. During thisphase, blue boxes or similar electrical boxes are mounted to wall studsat predetermined locations, so that outlets are 18″ and switches are 36″from the floor. Various box types are available, such as single-,double-, triple- or quadruple-wide configurations, among others. Afterthe boxes are installed, a journeyman electrician, following apredetermined layout, routes Romex.®. brand or equivalent power cablesthrough the framing to the appropriate boxes. A typical power cable hastwo solid core insulated conductors and a ground conductor, allsurrounded by a non-metallic sheath. The power cable is fed throughopenings in the rear or sides of the electrical boxes. The journeymantypically labels the conductors by writing a code on the insulation thatindicates the wiring connectivity and the type of module to be installedin each box. Then these cables are folded back into the boxes,unterminated, so as to be out of the way until the next phase. After allof the electrical wiring is routed in this manner, the electricalsubcontractors leave the construction site, waiting for othersubcontractors to finish their tasks.

The makeup phase corresponds to wall panel installation and painting.During this phase, the journeyman returns to the construction site toinstall modules into the electrical boxes. The journeyman retrieves thecable from each box, reviews the labeling, and connects the cableconductors to the appropriate module. One module choice is a duplexoutlet that receives standard two-prong or three-prong grounded ACplugs. The outlet can be wired fall-hot, where each outlet is alwaysconnected to power, or half-hot, where one outlet is connected to powerunder control of a wall switch. Another module choice is a switch, whichcan be a standard on/off switch, a three-way switch or a dimmer switch,for example. After conductors are wired to a module, the module andattached conductors are pushed into the electrical box and the module isattached to the top and bottom of the box with screws. Once all modulesare installed, the general contractor verifies the dwelling wiringagainst the electrical plans. If all of the wiring is correct, power canbe connected to the dwelling for the first time.

The final phase corresponds to construction thing and finishing work.During the trim phase, face plates are mounted over the open-end of theelectrical boxes, completing the standard electrical wiring process.

SUMMARY OF THE INVENTION Problems with Standard Wiring Construction

There are multiple problems with standard electrical wiringconstruction. From the electrical contractor perspective, there areunnecessary costs associated with installation. Two separate trips arerequired for each job site, one for the rough phase and one for themakeup phase. Further, a journeyman electrician is required for eachphase. During the makeup phase, installation of the wall panels candamage the work completed during the rough phase. One way in whichdamage occurs is router contact with exposed cables when drywallerscreate a hole to accommodate electrical box openings. Another form ofdamage occurs when drywall compound or paint fouls the exposed cables,insulation and labeling.

From the general contractor perspective, there are other problems withthe standard electrical wiring construction. Verification of theelectrical contractors work is not possible until after the makeupphase. Until then, the electrical cables are unterminated. After themakeup phase, however, miswiring typically requires cutouts in theinstalled wall panels and associated patches after corrections arecompleted. Further, the electrical system cannot be activated untilafter verification. Thus, during the rough and makeup phases,electricity for tools and lighting must be supplied by generators, whichcreate hazards due to fumes, fuel, and noise and are an unreliableelectrical source. In addition, until the trim phase is completed,unskilled personnel have access to the electrical cable. Tampering cancomprise the integrity of the electrical wiring and also create a safetyproblem after power is activated.

From a homeowners perspective, there are problems with repair of thestandard electrical wiring. FIG. 1 illustrates a prior art electricalwiring assembly 100, which includes a standard electrical box 110 and astandard duplex outlet 120. Replacement of a broken outlet 120 firstrequires removal of a face plate (not shown). The screws 130 that attachthe outlet 120 to the top and bottom of the electrical box 110 must beremoved next. The outlet 120 is then removed from the box 110 and theconductors 140 are removed by loosing the screws 150 on the outletsides. The process is then reversed to attach the conductors 140 to anew outlet 120 and mount the new outlet 120 into the electrical box 110.

The prior art outlet replacement procedure described above exposes thehomeowner to AC wiring upon removal of the face plate. This exposurecreates a shock hazard. Further, a homeowner's reluctance to change outbroken outlets or to spend the money to hire an electrician also createsa shock and a fire hazard from continued use of cracked, broken orexcessively worn outlets. In addition, the integrity of the originalwiring becomes questionable if a homeowner or other third party removesand replaces an outlet or switch. Miswiring by a third party can violatebuilding codes and create shock and fire hazards, such as inadvertentlyswitching the hot and neutral conductors, failing to attach groundwires, kinking or nicking conductors and improperly tighteningconnections.

BENEFITS OF THE PRESENT INVENTION

The safety electrical outlet and switch system according to the presentinvention, benefits the electrical contractor in several respects. Anaspect of the present invention is an electrical box, a wiring panelinstalled internally to the box and associated outlet and switch moduleswhich snap into and out of the panel without exposure to or access toelectrical system wiring attached behind the panel. The journeyman'swork is completed at the rough phase, when installation of the wiringpanel is complete. Thus, there is no need for the journeyman to returnto the job site during the makeup phase because any semi-skilledlaborer, following a punch-out code or other indicator on the panel, cansnap-in an appropriate outlet or switch module. Further, there is nowiring access after the rough phase, protecting wiring integrity. Also,there are no exposed conductors or parts inside the electrical box thatcan be inadvertently damaged during wall panel installation. Aprotective cover is provided that prevents fouling by drywall compoundor other materials during the makeup phase.

The safety electrical outlet and switch system according to the presentinvention also benefits the general contractor. Because wiring iscompleted during rough framing, verification and activation of thebuilding electrical system can be performed at the rough phase.Miswiring can be corrected before wall panels are installed and painted,eliminating cut and patch repairs. Early electrical system activationeliminates the need to use generators. Lack of third party access to thejourneyman's wiring preserves integrity after verification andeliminates shock exposure to other workers.

The present invention also benefits the homeowner. Replacement of brokensockets and switches can be easily and safely accomplished. Safety isenhanced by reducing exposure to electrical wiring and encouragingreplacement of defective outlets and switches. Further, maintenancecosts are reduced by reducing the need to hire an electrician forrepairs. Wiring integrity is insured by reducing the opportunity ofunqualified third parties to access the electrical system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a prior art outlet electrical wiringassembly;

FIG. 2 is a perspective view of a safety electrical outlet and switchsystem according to the present invention;

FIGS. 3A-B are exploded perspective views of an outlet assembly and aswitch assembly, respectively, of the safety electrical outlet andswitch system, illustrating box mount, electrical box, wiring panel,snap-in electrical modules and face plate portions;

FIGS. 4A-F are perspective views illustrating the removal andinstallation of snap-in electrical modules;

FIG. 4A is a front perspective view of an installed snap-in outletmodule;

FIG. 4B is a front perspective view of an unfastened snap-in outletmodule with extended extractor handles;

FIG. 4C is a front perspective view of an uninstalled snap-in outletmodule;

FIG. 4D is a front perspective view of an uninstalled snap-in switchmodule;

FIG. 4E is a front perspective view of an outlet module installed in awiring panel;

FIG. 4F is a front perspective view of a switch module installed in awiring panel;

FIGS. 5A-B are front and back perspective views, respectively, of a boxmount;

FIGS. 6A-B are front and back perspective views, respectively, of anelectrical box;

FIGS. 7A-F are perspective views of a wiring panel;

FIGS. 7A-B are front and back perspective views, respectively, of anassembled wiring panel;

FIG. 7C is a back perspective view of a wiring panel board;

FIG. 7D is a front perspective view of a wiring panel back cover;

FIGS. 7E-F are back and front perspective views, respectively, of wiringpanel internal conductors;

FIGS. 8A-F are perspective views of an outlet module;

FIGS. 8A-B are front and back perspective views, respectively, of anassembled outlet module;

FIG. 8C is a front perspective view of a mounting bracket;

FIG. 8D is a back perspective view of an outlet module front cover;

FIG. 8E is a front perspective view of an outlet module back cover;

FIGS. 8F-G are back and front perspective views, respectively, of outletmodule internal conductors;

FIGS. 9A-F are perspective views of a switch module;

FIGS. 9A-B are front and back perspective views, respectively, of anassembled switch module;

FIG. 9C is a back perspective view of a switch module front cover;

FIG. 9D is a front perspective view of a switch module back cover;

FIGS. 9E-F are back and front perspective views, respectively, of switchmodule internal conductors;

FIGS. 10A-D are perspective views of snap-on face plates;

FIGS. 10A-B are front and back perspective views of a flared rectangularface plate;

FIG. 10C is a front perspective view of a rectangular face plate;

FIG. 10D is a front perspective view of an oval face plate;

FIGS. 11A-B are front and back perspective views, respectively, of aprotective cover;

FIG. 12 is a front perspective view of a protective cover and a wiringpanel illustrating installation of the protective cover over the wiringpanel;

FIGS. 13A-C are front perspective views of a mounted electrical box;

FIG. 13A is a electrical-box-side front perspective view of a mountedelectrical box illustrating the releasable latch inside the box;

FIG. 13B-C are mounting-bracket-side front perspective views of amounted electrical box, illustrating the box in first and secondpositions, respectively, relative to the box mount;

FIGS. 14A-B are front perspective views of a mounted electrical box andassociated components installed on a wall stud;

FIG. 14A is a perspective view of a mounted electrical box with aninstalled wiring panel, illustrating box mount alignment;

FIG. 14B is a perspective view of a mounted electrical box with aninstalled protective cover illustrating plug accessibility to electricalpower during the rough framing phase of construction; and

FIG. 15 is a front perspective view of an adapter wiring panel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT System Overview

FIG. 2 illustrates one embodiment of an installed safety electricaloutlet and switch system 200 according to the present invention. Asshown in FIG. 2, the outlet and switch system 200 comprises a outletassembly 310 and a switch assembly 360. Each of these assemblies 310,360 provide a user-accessible electrical function. The outlet assembly310 is mounted in a wall 210 and functions to supply a user withelectrical power through a conventional AC plug inserted into an outletmodule 800. The switch assembly 360 is also mounted in the wall 210 andfunctions to allow a user to control electrical power to an outlet, alight or any of various electrical devices (not shown) by actuating aswitch module 900. The installed outlet assembly 310 includes a faceplate 1000 and an outlet module 800 mounted so that its visible portionis generally flush with the face plate 1000. The installed switchassembly 360 includes a face plate 1000 and a switch module 900 mountedso that its visible portion is in a plane generally parallel with theface plate 1000. The face plates 1000 are interchangeable between theoutlet assembly 310 and switch assembly 360 and include a flaredrectangular face plate, a rectangular face plate and an oval face plate,as described with respect to FIGS. 10A-D, below. Conveniently, the faceplates 1000 attach to or are removed from the outlet assembly 310 orswitch assembly 360 without the need for separate fastening devices,such as screws, and associated tools, as described with respect to FIG.10B, below.

FIGS. 3A-B illustrate embodiments of a safety electrical outlet andswitch system, comprising an outlet assembly 310 (FIG. 3A) and a switchassembly 360 (FIG. 3B). As shown in FIG. 3A, an outlet assembly 310comprises a box mount 500, an electrical box 600, a wiring panel 700, anoutlet module 800 and a face plate 1000. As shown in FIG. 3B, a switchassembly 360 comprises a box mount 500, an electrical box 600, a wiringpanel 700, a switch module 900 and a face plate 1000. The box mount 500,electrical box 600, wiring panel 700, outlet module 800 (FIG. 3A),switch module 900 (FIG. 3B), and face plate 1000 are described in detailbelow with respect to FIGS. 5A-B, 6A-B, 7A-F, 8A-G, 9A-F and 10A-D,respectively. In one embodiment, the main structural components of thebox mount 500, electrical box 600, wiring panel 700, outlet module 800,switch module 900, face plate 1000 and protective cover 1100 (FIG. 11)are composed of thermoplastics, such as nylon, polycarbonate or ABS. Inthat embodiment, the conductive components of the wiring panel 700,outlet module 800 and switch module 900 are brass or copper alloys. Oneof ordinary skill in the art will recognize that other materials can beused for the structural and conductive components of the presentinvention.

FIGS. 4A-F illustrate removal and installation of a snap-in outletmodule 800 (FIG. 4C) or a snap-in switch module 900 (FIG. 4D). FIG. 4Ashows an installed outlet assembly 310 with the face plate 1000 (FIG.3A) removed. An outlet module 800 is removably attached to the wiringpanel 700 (FIG. 4C) and secured with fasteners 809 to the electrical box600.

FIG. 4B shows the outlet module 800 during removal from, or installationinto, the electrical box 600. During removal, the fasteners 809 areunfastened to release the outlet module 800 from the electrical box 600and extend the extractor handles 824, as shown. The extended extractorhandles 824 are manually gripped and pulled to unsnap the outlet module800 from the wiring panel 700 (FIG. 4C). The outlet module 800 is thenremoved from electrical box 600, as shown in FIG. 4C. Duringinstallation, the process is reversed. The extended extractor handles824 are pushed into the outlet module 800, and the outlet module 800 issecured to the electrical box 600, as shown in FIG. 4A, using thefasteners 809 to attach to the module mounting posts 620 (FIG. 4C)

FIG. 4C shows an outlet module 800 during installation into or removalfrom the electrical box 600. For installation, the outlet module 800 isplaced at the electrical box open front face 602, as shown. The outletmodule 800 is then inserted into the module compartment 400 interior tothe electrical box 600 between the front face 602 and the wiring panel700. The top module fixture 830 and bottom module fixture 840 engage thetop panel fixture 710 and bottom panel fixture 720, respectively. Theoutlet module 800 is then pressed against the wiring panel 700, whichsnaps the outlet module 800 into the wiring panel 700, electricallyconnecting the outlet module 800 and wiring panel 700. The outlet module800 is then secured to the electrical box 600, as described above withrespect to FIG. 4B.

FIG. 4D shows a switch module 900 during installation into or removalfrom the electrical box 600. For installation, the switch module 900 isplaced at the electrical box front face 602, as shown. The switch module900 is then inserted into the module compartment 400 interior to theelectrical box 600. The top module fixture 930 and bottom module fixture940 engage the top panel fixture 710 and bottom panel fixture 720,respectively. The switch module 900 is then pressed against the wiringpanel 700, which snaps the switch module 900 into the wiring panel 700,electrically connecting the switch module 900 and wiring panel 700. Theswitch module 900 is then secured to the electrical box 600, in a mannersimilar to that described above with respect to FIG. 4B.

FIG. 4E shows the outlet module 800 installed into the wiring panel 700.The outlet module back cover 804 faces the wiring panel front side 702.The wiring panel top guides 712 fit within the outlet module top slots834, and the wiring panel bottom guides 722 fit within the outlet modulebottom slots 844.

FIG. 4F shows the switch module 900 installed into the wiring panel 700.The switch module back cover 904 faces the wiring panel front side 702.The wiring panel top guides 712 fit within the switch module top slots934, and the wiring panel bottom guides 722 fit within the switch modulebottom slots 944.

Box Mount

FIGS. 5A-B show a box mount 500, which attaches to a framing stud andprovides a slidable attachment for the electrical box 600 (FIGS. 6A-B).As shown in FIG. 5A, the box mount 500 has a stud plate 510, fastenerholders 520, mounting brackets 530, grooves 540, a latch channel 550 andcatch slots 560. The stud plate 510 has a box side 512, a stud side 518(FIG. 5B), and a leading edge 502 that functions as a stud alignmentguide. The fastener holders 520 receive and retain fasteners 522, suchas staples as shown. The box mount 500 is attached to a wall stud withthe stud side 518 flush against the stud and with the leading edge 502aligned with a stud edge. The fasteners 522 are hammered or otherwisedriven into the stud through apertures 570 (FIG. 5B) on the stud side518 (FIG. 5B). Attachment of the box mount to a wall stud is describedin further detail with respect to FIG. 14A, below. The electrical box600 (FIGS. 6A-B) is attached to the box mount 500 by placing theelectrical box 600 (FIGS. 6A-B) adjacent the area between the mountingbrackets 530, with the latch 650 (FIGS. 6A-B) adjacent the channel 550.The slides 630 (FIGS. 6A-B) are inserted into the mounting brackets 530and the guides 640 (FIGS. 6A-B) into the grooves 540, as described infurther detail with respect to FIG. 13A, below. The catch slots 560removably retain the electrical box 600 (FIGS. 6A-B) at various fixedpositions, as described in further detail with respect to FIGS. 13B-C,below.

Electrical Box

FIGS. 6A-B illustrate an electrical box 600. The electrical box 600 hasouter dimensions generally consistent with conventional electricalboxes. The electrical box 600 has an open front face 602 and a back face604. As shown in FIGS. 6A-B, the electrical box 600 has a mounting side606 and an opposite gripping side 608. The mounting side 606 has slides630, guides 640, a latch 650, position indicators 660, a finger grip 670and apertures 680. The slides 630 and guides 640 mate with correspondingbrackets 530 (FIG. 5A) and grooves 540 (FIG. 5A) on the box mount 500(FIGS. 5A-B), as described with respect to FIG. 13A, below. The latch650 has a spring portion 652 and a tab portion 654. The spring portion652 is attached to the electrical box 600 along the back face 604 andextends along the mounting side 606, terminating with the tab portion654. The tab portion 654 extends from the spring portion 652 generallyperpendicularly to the mounting side 606, away from the electrical box600. When the electrical box 600 is attached to the box mount 500 (FIGS.5A-B), the catch 654 is configured to engage in any of the catch slots560 (FIGS. 5A-B). The finger grip 670 is utilized to manually grip andposition the electrical box 600 relative to the box mount 500 (FIGS.5A-B) according to the position indicators 660, as described in furtherdetail with respect to FIGS. 13B-C, below. The apertures 680 are locatedon the back face 604 for routing power cable through the back face 604and into the interior of the electrical box 600. In another embodiment,a center aperture (not shown) is included, also for routing power cableinto the interior of the electrical box 600.

As shown in FIGS. 6A-B, the front face 602 and interior of theelectrical box 600 are configured for installment of the wiring panel700 (FIGS. 7A-B), the protective cover 1100 (FIG. 11A-B), the outletmodule 800 (FIGS. 8A-B) and the switch module 900 (FIGS. 9A-B). Theinterior of the electrical box 600 includes panel mounting posts 610located along each interior corner edge and module mounting posts 620located along the center of the interior top and bottom faces. Each ofthe panel mounting posts 610 is recessed from the front face 602 and hasa centered hole 612. In one embodiment, the panel mounting posts 610 arerecessed at least about 1.25 inches from the front face 602 to avoiddamage to the installed wiring panel 700 (FIGS. 7A-B) during the makeupphase of construction and, in particular, during wall panelinstallation. Each of the module mounting posts 620 is flush with thefront face 602 and has a centered hole 622.

The wiring panel 700 (FIGS. 7A-B) is installed in the interior of theelectrical box 600 with panel back side 704 (FIG. 7B) abutting the panelmounting posts 340. The wiring panel 700 (FIGS. 7A-B) is secured withinthe electrical box 600 with fasteners 707 (FIG. 7C) threaded orotherwise inserted into the centered holes 612, as described withrespect to FIG. 14A, below. Similarly, the protective cover 1100 (FIGS.11A-B) is installed in the interior of the electrical box 600 againstthe panel mounting posts 340 and secured with fasteners 707 (FIG. 12)inserted through the centered holes 612, as described with respect toFIG. 14B, below. The outlet module 800 (FIGS. 8A-B) and the switchmodule 900 (FIGS. 9A-B) are snapped into the wiring panel 700 (FIGS.7A-D) and secured to the module mounting posts 620 with the fasteners809 (FIGS. 4A-D) threaded or otherwise inserted into centered holes 622,as described with respect to FIGS. 4A-D, above.

Wiring Panel

FIGS. 7A-F illustrate the generally planar wiring panel 700, which has aboard 701, internal conductors 703, a back cover 705 and fasteners 707.The board 701 (FIG. 7C) retains the internal conductors 703 (FIGS.7E-F), the back cover 705 (FIG. 7D) and the fasteners 707 (FIG. 7C) ofthe assembled wiring panel 700 (FIGS. 7A-B). FIGS. 7A-B illustrate theassembled wiring panel 700.

As shown in FIGS. 7A-B, the wiring panel 700 has a front side 702 and aback side 704. As shown in FIG. 7A, the front side 702 has a top panelfixture 710, a bottom panel fixture 720 and an socket 730. The top panelfixture 710 and bottom panel fixture 720 are configured to accept,removably retain and electrically connect to an outlet module 800 (FIGS.8A-B), a switch module 900 (FIGS. 9A-B) or similar module that providesa user-accessible electrical functions. The top panel fixture 710 hastop guides 712, top latches 714, top panel contacts 756, 766 and aground connector 718, all extending in a direction normal to the frontside 702. A ground panel contact 776 (FIG. 7F) is accessible through theground connector 718. The bottom panel fixture 720 has bottom guides722, bottom latches 724 and bottom panel contacts 757, 767, also allextending in a direction normal to the front side 702.

Also shown in FIG. 7A, the socket 730 has a hot slot 732, a neutral slot734 and a ground hole 736. The socket 730 is configured to accept andelectrically connect to a standard plug, which is inserted into thesocket 730 so that the plug's hot prong, neutral prong and ground postenters the hot slot 732, neutral slot 734 and ground hole 736,respectively, and electrically connects with the hot socket contact 758(FIGS. 7E-F), neutral socket contact 768 (FIGS. 7E-F) and ground socketcontact 778 (FIGS. 7E-F), respectively.

One particularly advantageous feature of the wiring panel 700 is thesocket 730. The socket 730 allows power to be supplied to a constructioncrew after the wiring panel 700 has been wired and building electricalsystem tested and activated, prior to the makeup phase, as described infurther detail with respect to FIGS. 14A-B, below. Another particularlyadvantageous feature is that a user's exposure to the top panel contacts756, 766 is minimized by the top guides 712, top latches 714 and groundconnector 718 that shield the top panel contacts 756, 766 on all foursides and the front. Further, the ground connector 718 separates thefirst top panel contact 756 from the second top panel contact 766,reducing the possibility of a short between the top panel contacts 756,766. Similarly, the bottom guides 722 and bottom latches 724 shield thebottom panel contacts 757, 767 from the sides and the front.

As shown in FIG. 7B, the wiring panel back side 704 has a back cover705, first buss cable connectors 752, 754, second buss cable connectors762, 764 and a ground buss cable connector 772. A first buss breakaway755 can be removed during wiring of the wiring panel 700 in order toisolate the first buss top cable connector 752 from the first bussbottom cable connector 754. Similarly, a second buss breakaway 755 canbe removed in order to isolate the second buss top cable connector 762from the second buss bottom cable connector 764. During installation ofthe wiring panel 700 into the electrical box 600 (FIG. 6A-B), describedwith respect to FIG. 14A, below, one or more electrical cables, such aspower or equivalent, are routed through the electrical box apertures 680and the wires within the cables are attached to the cable connectors752, 754, 762, 764. The wire connections are made by hooking anuninsulated conductor portion of the wires around the respective screwsof the cable connectors 752, 754, 762, 764 and tightening the screws sothat the conductors are secured between the screws and their respectivebusses 750, 760, 770 (FIGS. 7E-F), as is well-known in the art. Theparticular wiring configuration is a function of a master wiring planfor the building under construction and the module type to be installedin the wiring panel 700. Several wiring panel 700 wiring configurationsare described below.

FIG. 7C illustrates the back side 704 of the wiring panel board 701,which has mounting post slots 706, mounting holes 708 and grips 709.These features are used to install the wiring panel 700 and secure itwith fasteners 707 within the electrical box 600 (FIGS. 6A-B), asdescribed with respect to FIG. 14A, below. The wiring panel board 701also has raised chambers 782, 784, 786 that retain the internalconductors 703 (FIGS. 7E-F) and binding sockets 781.

FIG. 7D illustrates the front of the wiring panel back cover 705. Theback cover 705 has a connector aperture 792 that accommodates the groundbuss cable connector 772 (FIG. 7B), prong apertures 794, 796 thataccommodate the prongs of a standard plug inserted into the wiring panelsocket 730 (FIG. 7A), and a ground post aperture 798 that accommodatesthe ground post of the inserted standard plug. Binding posts 791press-fit into corresponding binding sockets 781 (FIG. 7C) on the panelback side 704 (FIG. 7C) for joining the back cover 705 to the wiringpanel board 701 (FIG. 7C).

As shown in FIGS. 7E-F, the internal conductors 703 include a first buss750, a second buss 760 and a ground buss 770. The busses 750, 760, 770are retained within the wiring panel board raised chambers 782, 784,786, respectively. The first buss 750 electrically connects the firsttop panel contact 756, the first buss top cable connector 752, the firstbuss breakaway 755, the first bottom panel contact 757, the first bussbottom cable connector 754 and the hot socket contact 758. Similarly,the second buss 760 electrically connects the second top panel contact766, the second buss top cable connector 762, the second buss breakaway765, the second bottom panel contact 767, the second buss bottom cableconnector 764 and the neutral socket contact 768. The ground buss 770electrically connects the ground panel contact 776, the ground busscable connector 772 and the socket ground contact 778. If the first bussbreakaway 755 is removed, the first top panel contact 756 and the firstbuss top cable connector 752 are electrically isolated from the firstbottom panel contact 757, the first buss bottom cable connector 754 andthe hot socket contact 758. Likewise, if the second buss breakaway 765is removed, the second top panel contact 766 and the second buss topcable connector 762 are electrically isolated from the second bottompanel contact 767, the second buss bottom cable connector 764 and theneutral socket contact 768. The panel contacts 756, 766, 757, 767provide contact surfaces for electrical connection to outlet modulecontacts 856, 866, 857, 867 or switch module contacts 956, 966, 957, 967as described with respect to FIGS. 8F-C and FIGS. 9E-F, below.

Outlet Module

FIGS. 8A-G illustrate an outlet module 800, which has a front cover 802,an attachment assembly 820, a back cover 804 and internal conductors806. FIGS. 8A-B illustrate an assembled outlet module 800, FIG. 8Cillustrates the front of the attachment assembly 820, FIG. 8Dillustrates the back of the outlet module front cover 802, FIG. 8Eillustrates the front of the outlet module back cover 804, and FIGS.8F-G illustrate the outlet module internal conductors 806. As shown inFIG. 8A, the front cover 802 and back cover 804 are glued, welded orotherwise attached together to form the body of the outlet module 800.The attachment assembly 820 is retained by the front cover 802, asdescribed with respect to FIG. 8C, below, and provides the means tosecure the outlet module 800 to an electrical box 600 (FIGS. 6A-B). Thefront cover 802 has a raised socket portion 810, which includes a topsocket 811 and a bottom socket 816, each compatible with a standard ACplug. The top socket 811 has a hot slot 812, a neutral slot 813 and aground post hole 814, which provide plug access to the top socketcontacts 854, 864, 874 (FIGS. 8F-G). Similarly, the bottom socket 816has a hot slot 817, a neutral slot 818 and a ground post hole 819, whichprovide plug access to the bottom socket contacts 855, 865, 875 (FIGS.8F-G).

As shown in FIG. 5B, the back cover 804 includes a top module fixture830 and a bottom module fixture 840. The top module fixture 830 includestop contact housings 832 and top slots 834. The bottom module fixture840 includes bottom contact housings 842, bottom slots 844, and a modulekey 846. The top contact housings 832 contain top outlet contacts 856,866, and the bottom contact housings 842 contain bottom outlet contacts857, 867. A ground bar 876 extends from the back cover 804 between thetop contact housings 832.

As shown in FIG. 8C, the attachment assembly 820 includes a bracket 822and extractor handles 824. The bracket 822 is a one-piece conductiveelement that fits around the outside of the front cover 802. The sidesof the front cover 802 (FIG. 8D) include protruding cover catches 803(FIG. 8D) that extend through bracket slots 823 to retain the attachmentassembly 820 and to retain a cover plate 1000 (FIGS. 10A-D), asdescribed with respect to FIG. 10B, below. The extractor handles 824 aremoveably retained by the bracket 822, and each handle 824 has a crossbar826 and arms 828. At the tip of each handle arm 828 is a clasp 829. Inthe center of each handle crossbar 826 is a fastener hole 827. Afastener 809, such as a screw or equivalent, is moveably retained withinthe fastener hole 827. The extractor handles 824 each have a closedposition, shown at the top of FIG. 8C, and an open position, shown atthe bottom of FIG. 8C. In the closed position, the handles 824 arepushed in so that the crossbar 826 fits against the bracket 822. In theopen position, the handles 824 are pulled out so that they extend awayfrom the bracket 822, with the arm clasps 829 each clasping an edgeportion of the bracket 822. With the handles 824 in the closed position,the outlet module can be secured to an electrical box 600 (FIGS. 6A-B),as described with respect to FIG. 4A, above. With the handles 824 in theopen position, the outlet module can be removed from a wiring panel 700(FIGS. 7A-B), as described with respect to FIG. 4B, above.

As shown in FIG. 8D, the front cover 802 has binding posts 883 thatpress-fit into corresponding binding sockets 893 (FIG. 8E) on the backcover 804 (FIG. 8E) for joining the front cover 802 and back cover 804(FIG. 8E). The front cover 802 also has a raised portion 881 thatretains the ground buss 870 (FIGS. 8F-G) and the adjacent top and bottombusses 851, 852, 861, 862 (FIGS. 8F-G).

As shown in FIG. 8E, the back cover 804 has top recessed portions 891within the top contact housings 832 that retain the top outlet contacts856, 866 (FIGS. 8F-G). Similarly, the back cover 804 has bottom recessedportions 892 within the bottom contact housings 842 that retain thebottom outlet contacts 857, 867 (FIGS. 8F-G).

As shown in FIGS. 8F-G, the internal conductors 806 of the outlet module800 include a top hot buss 851, a bottom hot buss 852, a top neutralbuss 861, a bottom neutral buss 862, and a ground buss 870. The top hotbuss 851 has a top socket hot contact 854 and a top hot module contact856. The bottom hot buss 852 has a bottom socket hot contact 855 and abottom hot module contact 857. The top neutral buss 861 has a top socketneutral contact 864 and a top neutral module contact 866. The bottomneutral buss 862 has a bottom socket neutral contact 865 and a bottomneutral module contact 867. The ground buss 870 has a ground bar 876, atop socket ground contact 874 and a bottom socket ground contact 875.

Outlet Module Installation

In reference to FIG. 8B, an outlet module 800 is installed in anelectrical box 600 (FIGS. 6A-B) as described with respect to FIGS. 4A-C,E above. An outlet module 800 and the wiring panel 700 (FIGS. 7A-B) arekeyed to prevent the installation of an outlet module 800 into a modulecompartment 400 (FIG. 4C) with an incorrect, i.e. upside-downorientation. Specifically, the module key 846 must engage the bottompanel fixture 720 (FIG. 7A) and the ground bar 876 must engage theground connector 718 (FIG. 7A) for proper module orientation. The modulekey 846 will not engage the top panel fixture 710 (FIG. 7A) and theground bar 876 will not engage the bottom panel fixture 720 (FIG. 7A) inthe improper orientation. That is, the module key 846 and ground bar 876function as keyed structures of the outlet module 800, and the groundconnector 718 (FIG. 7A) and bottom panel fixture 720 (FIG. 7A), inparticular the gap between the guides and latches 722, 724 (FIG. 7A),function as keyed structures of the wiring panel 700 (FIG. 7A). Thekeyed structures of the outlet module 800 and the corresponding keyedstructures of the wiring panel 700 (FIG. 7A) insure proper orientationof the installed outlet module 800.

In reference to FIGS. 8F-G, when an outlet module 800 (FIGS. 8A-B) isattached to a wiring panel 700 (FIGS. 7A-B), the top hot module contact856 is electrically connected to the first top panel contact 756 (FIGS.7E-F), the top neutral module contact 866 is electrically connected tothe second top panel contact 766 (FIGS. 7E-F), the bottom hot modulecontact 857 is electrically connected to the first bottom panel contact757 (FIGS. 7E-F), and the bottom neutral module contact 867 iselectrically connected to the second bottom panel contact 767 (FIGS.7E-F). In this configuration, if the wiring panel 700 (FIGS. 7A-B) iswired in a full-hot configuration, as described below, then the top 851and bottom 852 hot busses are hot, the top 861 and bottom 862 neutralbusses are neutral and the ground buss 870 is grounded. In this manner,the top socket contacts 854, 864, 874 provide power to a standard ACplug inserted into the top socket 811 (FIG. 8A) and the bottom socketcontacts 855, 865, 875 provide power to a standard AC plug inserted intothe bottom socket 816 (FIG. 8A). Similarly, if the wiring panel 700(FIGS. 7A-B) is wired in a half-hot configuration, as described below,then a standard AC plug inserted into (typically) the bottom socket 816(FIG. 8A) is provided power and a standard plug inserted into(typically) the top socket 811 (FIG. 8A) is provided switched power.

Also in reference to FIGS. 8F-G, the outlet module contacts 856, 857,866, 867 are spring contacts each extending from busses 851, 852, 861,862 and each having a generally V-shaped contact point. Duringinstallation, as the outlet module 800 (FIGS. 8A-B) is pressed againstthe wiring panel 700 (FIGS. 7A-B) the top and bottom module contacts856, 857, 866, 867 press against the corresponding top latches 714 (FIG.7A) and bottom latches 724 (FIG. 7A). These latches 714, 724 (FIG. 7A)are flexible, spring-like structures extending from the wiring panelboard 701 (FIG. 7A) and having a hooked tip. When sufficient pressingforce is applied, the spring contacts 856, 857, 866, 867 and the springlatches 714, 724 (FIG. 7A) flex until the contact points pass over andclear the hooked tips and connect with the contact surfaces of the panelcontacts 756, 757, 766, 767 (FIG. 7A), with the hooked tip latches 714,724 retaining the V-shaped module contacts 856, 857, 866, 867. At theinstant the contact points pass over the latch tips, the contacts 856,857, 866, 867 and latches 714, 724 (FIG. 7A) quickly return to theirunflexed positions with a mechanical action that is referred to hereinas a snap, snapping or snap-in. A similar mechanical action occurs whenthe contacts 856, 857, 866, 867 and latches 714, 724 (FIG. 7A) aredisconnected and is referred to herein as an unsnap, unsnapping orsnap-out.

The snapping and unsnapping of the outlet module during installation andremoval creates positive tactile feedback that both a mechanical andelectrical connection has been made between the outlet module 800 (FIGS.8A-B) and the wiring panel 700 (FIGS. 7A-B). This is in contrast to aplug-in electrical connection, such as when the prongs of a standard ACplug are inserted into or removed from a standard socket, where thetactile feedback is that of slight, continual resistance to the movementof the plug rather than the build-up and quick release of resistance forthe snap-in module installation into the module compartment 400 (FIG.4C) and attached to the wiring panel 700 (FIGS. 7A-B) or thecorresponding snap-out module removal according to the presentinvention.

Wiring Panel Outlet Module Wiring

In reference to FIG. 7B, the wiring panel 700 is wired for a fall-hotduplex outlet by connecting the black, white and green wires of a singlepower cable to, for example, the first buss bottom cable connector 754,the second buss bottom cable connector 764, and ground buss cableconnector 772, respectively. In this manner, both of the duplex sockets811, 816 (FIG. 8A) of an installed outlet module 800 (FIGS. 8A-B) arealways hot.

Also in reference to FIG. 7B, the wiring panel 700 is wired for ahalf-hot duplex outlet by connecting the black and white wires of onepower cable as described above. The black and white wires of a secondpower cable are connected to the top hot 752 and neutral 762 connectors,respectively. Break away portions 755, 765 of the hot buss 750 andneutral buss 760, respectively, are removed, isolating the top hotconnector 752 from the bottom hot connector 754 and the top neutralconnector 762 from the bottom neutral connector 764. This also isolatesthe top panel contacts 756, 766 (FIG. 7A) from the bottom panel contacts757, 767 (FIG. 7A). In this manner, one of the duplex sockets 816 (FIG.8A) of an installed outlet module 800 is always hot and the other duplexsocket 811 (FIG. 8A) is on or off, as controlled by a nearby switch thatroutes power to the second power cable.

Switch Module

FIGS. 9A-F illustrate a switch module 900, which has a front cover 902,a rocker switch 910, an attachment assembly 820, a back cover 904 andinternal conductors 906. FIGS. 9A-B illustrate an assembled switchmodule 900, FIG. 9C illustrates the back of a switch module front cover902, FIG. 9D illustrates the front of a switch module back cover 904,and FIGS. 9E-F illustrate the switch module internal conductors 906. Asshown in FIG. 9A, the front cover 902 and back cover 904 are glued,welded or otherwise attached together to form the body of the switchmodule 900. The attachment assembly 820 is retained by the front cover802, as described with respect to FIG. 8C, above, and provides the meansto secure the switch module 900 to an electrical box 600 (FIGS. 6A-B).The front cover 902 incorporates a rocker switch 910, which has an upperportion 912 with a raised button 913 and a lower portion 914 with anindented button 915. The rocker switch 910 has a first position with theupper portion 912 proximate the front cover 902, as shown, and a secondposition with the lower portion 914 proximate the front cover 902.

As shown in FIG. 9B, the back cover 904 includes a top module fixture930 and a bottom module fixture 940. The top module fixture 930 includestop contact housings 932 and top slots 934. The bottom module fixture940 includes bottom contact housings 942, bottom slots 944, and a wiringpanel key 946. The top contact housings 932 contain top module contacts956, 966, and the bottom contact housings 842 contain bottom modulecontacts 957, 967. A ground bar 976 extends from the back cover 904between the top contact housings 932.

As shown in FIG. 9C, the front cover 902 has a binding post 984 thatpress-fits into a corresponding binding socket 994 (FIG. 9D) on the backcover 904 (FIG. 9D) and binding sockets 983 that accept back coverbinding posts 993, all for joining the front cover 902 and back cover904 (FIG. 9D). The front cover 902 also has a switch aperture 981through which protrudes a lever portion 918 of the rocker switch 910.The sides of the front cover 902 include protruding cover catches 903that extend through bracket slots 823 (FIG. 5C) to retain the attachmentassembly 820 (FIGS. 9A-B) and to retain a cover plate 1000 (FIGS.10A-D), in a manner similar to that described with respect to FIG. 5C,above.

As shown in FIG. 9D, the back cover 904 has top recessed portions 991within the top contact housings 932 that retain the top module contacts956, 966 (FIGS. 9E-F). Similarly, the back cover 904 has bottom recessedportions 992 within the bottom contact housings 942 that retain thebottom module contacts 957, 967 (FIGS. 9E-F). The back cover 904 alsohas carrier supports 998 for the carrier 960 (FIGS. 9E-F), a busssupport 997 for the second bottom buss 962 (FIGS. 9E-F), a support 996for the top upper throw contact 967 (FIGS. 9E-F), as well as otherraised structures (not shown) for supporting the first bottom buss 952(FIGS. 9E-F) and the first top buss 951 (FIGS. 9E-F). A spring aperture999 retains the slide spring 925 (FIG. 9E).

As shown in FIGS. 9E-F, the switch module internal conductors 906include a first top buss 951, a second top buss 961, a first bottom buss952 and a second bottom buss 962. The first top buss 951 electricallyconnects the first top module contact 956 and the top pole 954. Thefirst bottom buss 952 electrically connects the first bottom modulecontact 957 and the bottom pole 955. The second top buss 961electrically connects the second top module contact 966 and the carrier960. The carrier 960 has a top lower throw contact 964 and a bottomupper throw contact 968. The second bottom buss 962 electricallyconnects the second bottom module contact 967 and the bottom lower throwcontact 965. A center buss 963 electrically connects the top upper throwcontact 967 and the bottom lower throw contact 965.

Also shown in FIGS. 9E-F, a slide 920 has a switch lever aperture 921,top stops 926 and bottom stops 927. The rocker switch lever 918 (FIG.9C) fits into the lever aperture 921. The spring 925 provides resistanceto movement of the slide 920 and a corresponding tactile tension to therocker switch 910 (FIG. 9A). When the rocker switch 910 (FIG. 9A) is inits first position (as shown in FIG. 9A, the lever 918 (FIG. 9C) is inits down position (as shown in FIG. 9C), which moves the slide 920 inits down position. When the rocker switch 910 (FIG. 9A) is in its secondposition, the lever 918 (FIG. 9C) is in its up position, which moves theslide 920 to its up position (as shown in FIGS. 9E-F). In the slideupper position, the lower portions of the stops 926, 927 move the poles954, 955 so as to connect with the upper throw contacts 967, 968. In theslide lower position, the upper portions of the stops 926, 927 move thepoles 954, 955 so as to connect with the lower throw contacts 964, 965.

Switch Module Installation

In reference to FIG. 9B, a switch module 900 is installed in anelectrical box 600 (FIGS. 6A-B) as described with respect to FIGS. 4Dand F, above. A switch module 900 and the wiring panel 700 (FIGS. 7A-B)are keyed to prevent the installation of a switch module 900 into amodule compartment 400 (FIG. 4D) with an incorrect, i.e. upside-downorientation. Specifically, the module key 946 must engage the bottompanel fixture 720 (FIG. 7A) and the ground bar 976 must engage theground connector 718 (FIG. 7A) for proper module orientation. The modulekey 946 will not engage the top panel fixture 710 (FIG. 7A) and theground bar 976 will not engage the bottom panel fixture 720 (FIG. 7A) inthe improper orientation. That is, the module key 946 and ground bar 976function as keyed structures of the switch module 900, and the groundconnector 718 (FIG. 7A) and bottom panel fixture 720 (FIG. 7A), functionas keyed structures of the wiring panel 700 (FIG. 7A), as described withrespect to the outlet module 800 (FIGS. 8A-B), above. The keyedstructures of the switch module 900 and the corresponding keyedstructures of the wiring panel 700 (FIG. 7A) insure proper orientationof the installed switch module 900.

In reference to FIGS. 9E-F, when a switch module 900 (FIGS. 9A-B) isattached to a wiring panel 700 (FIGS. 7A-B), the first top modulecontact 956 is electrically connected to the first top panel contact 756(FIGS. 7E-F), the second top module contact 966 is electricallyconnected to the second top panel contact 766 (FIGS. 7E-F), the firstbottom module contact 957 is electrically connected to the first bottompanel contact 757 (FIGS. 7E-F), and the second bottom module contact 967is electrically connected to the second bottom panel contact 767 (FIGS.7E-F).

Also in reference to FIGS. 9E-F, the switch module contacts 956, 957,966, 967 are spring contacts and each having a generally V-shapedcontact point. During installation, as the switch module 800 (FIGS.8A-B) is pressed against the wiring panel 700 (FIGS. 7A-B) the top andbottom module contacts 956, 957, 966, 967 press against thecorresponding top latches 714 (FIG. 7A) and bottom latches 724 (FIG. 7A)and eventually snap together, in a manner similar to that described withrespect to the outlet module 800 (FIGS. 8A-B), above. The snapping andunsnapping of the switch module during installation and removal createspositive tactile feedback that both a mechanical and electricalconnection has been made between the switch module 900 (FIGS. 9A-B) andthe wiring panel 700 (FIGS. 7A-B) within the module compartment 400(FIG. 4D).

Switch Module Configurations and Associated Wiring Panel Wiring SPSTSwitch

As shown in FIGS. 9E-F, the internal conductors 906 can be configured asa SPST (single-pole, single-throw) switch, a DPST (double-pole,single-throw) switch, a three-way switch, and a four-way switch. If thetop upper throw contact 967, the lower throw contact 964 and the bottomupper throw contact 968 are removed, the lower pole 955 and bottom lowerthrow contact 965 form a SPST switch. When the rocker switch 910 (FIG.9A) is moved to its first position, causing the slide 920 to move to itslower position, the pole 955 connects with the bottom lower throwcontact 965, electrically connecting the first bottom module contact 957with the second bottom module contact 967. Likewise, when the rockerswitch 910 (FIG. 9A) is moved to its second position, causing the slide920 to move to its upper position, the pole 955 disconnects from thebottom lower throw contact 965, electrically disconnecting the firstbottom module contact 957 with the second bottom module contact 967.Thus, movement of the rocker switch 910 (FIG. 9A) between its first andsecond positions alternately makes and breaks an electrical connectionbetween the bottom module contacts 957, 967.

In reference to FIG. 7B, the wiring panel 700 is wired for a SPSTswitch, as described above, by connecting the black (hot) wire of afirst power cable to the first buss bottom cable connector 754 and theblack wire of a second power cable to the second buss bottom cableconnector 764. In this manner, when the first bottom module contact 757is switched to the second bottom module contact 767 via an installedSPST switch module 900 (FIGS. 9A-B), as described with respect to FIGS.9E-F, above, power is switched between the first and second powercables.

DPST Switch

As shown in FIGS. 9E-F, if the top upper throw contact 967 and thebottom upper throw contact 968 are removed, the upper pole 954 inconjunction with the top lower throw contact 964 and the lower pole 955in conjunction with the bottom lower throw contact 965 form a DPSTswitch. When the rocker switch 910 (FIG. 9A) is moved to its firstposition, causing the slide 920 to move to its lower position, the poles954, 955 connect with the corresponding lower throw contacts 964, 965electrically connecting the top module contacts 956, 966 and, also,electrically connecting the bottom module contacts 957, 967. Likewise,when the rocker switch 910 (FIG. 9A) is moved to its second position,causing the slide 920 to move to its upper position, the poles 954, 955disconnect with the corresponding lower throw contacts 964, 965electrically disconnecting the top module contacts 956, 966 and, also,electrically disconnecting the bottom module contacts 957, 967. Thus,movement of the rocker switch 910 (FIG. 9A) between its first and secondpositions alternately makes and breaks an electrical connection betweenthe top module contacts 956, 966 and, also, alternately makes and breaksan electrical connection between the bottom module contacts 957, 967.

In reference to FIG. 7B, the wiring panel 700 is wired for a DPSTswitch, as described above, by removing the first 755 and second 765buss breakaways to isolate the top panel contacts 756, 766 (FIGS. 7E-F)from the bottom panel contacts 757, 767 (FIGS. 7E-F) and, hence,isolating the top module contacts 956, 966 (FIGS. 9E-F) from the bottommodule contacts 957, 967 (FIGS. 9E-F) of an installed DPST switchmodule. The black and white wires of a first power cable are connectedto the first buss bottom 754 and top 752 cable connectors, respectively.The black and white wires of a second power cable are connected to thesecond buss bottom 764 and top 762 cable connectors, respectively. Inthis manner, when the first top panel contact 756 is switched to thesecond top panel contact 766 and the first bottom panel contact 757 isswitched to the second bottom panel contact 767 via an installed DPSTswitch module 900 (FIGS. 9A-B), as described with respect to FIGS. 9E-F,above, an electrical load can be switched between the first and secondpower cables.

Three-Way Switch

As shown in FIGS. 9E-F, if the top upper throw contact 967 is removed,the upper pole 954 in conjunction with the top lower throw contact 964and the lower pole 955 in conjunction with the bottom lower and upperthrow contacts 965, 968 form a three-way switch. When the rocker switch910 (FIG. 9A) is moved to its first position, causing the slide 920 tomove to its lower position, the poles 954, 955 connect with thecorresponding lower throw contacts 964, 965 electrically connecting thetop module contacts 956, 966 and, also, electrically connecting thebottom module contacts 957, 967. When the rocker switch 910 (FIG. 9A) ismoved to its second position, causing the slide 920 to move to its upperposition, the top pole 954 is disconnected. The bottom pole 955,however, is connected with the bottom upper throw contact 968, which isconnected to the second top module contact 966 via the carrier 960 andthe second top buss 961. Thus, movement of the rocker switch 910 (FIG.9A) between its first and second positions alternately makes and breaksan electrical connection between the bottom module contacts 957, 967and, also, electrically connects the second top module contact 966,alternately, with the first top module contact 956 and the first bottommodule contact 957.

Four-Way Switch

As shown in FIGS. 9E-F, if all of the conductors 906 are in place, theupper pole 954 in conjunction with the top lower and upper throwcontacts 964, 967 and the lower pole 955 in conjunction with the bottomlower and upper throw contacts 965, 968 form a four-way switch. When therocker switch 910 (FIG. 9A) is moved to its first position, causing theslide 920 to move to its lower position, the poles 954, 955 connect withthe corresponding lower throw contacts 964, 965 electrically connectingthe top module contacts 956, 966 and, also, electrically connecting thebottom module contacts 957, 967. When the rocker switch 910 (FIG. 9A) ismoved to its second position, causing the slide 920 to move to its upperposition, the poles 954, 955 connect with the corresponding upper throwcontacts 967, 968, electrically connecting the top first module contact956 with the bottom second module contact 967 via the center buss 963and, also, electrically connecting the bottom first module contact 957with the top second module contact 966 via the carrier 960 and thesecond top buss 961. Thus, movement of the rocker switch 910 (FIG. 9A)between its first and second positions makes an electrical connectionbetween the bottom module contacts 957, 967 and, also, between the topmodule contacts 956, 966, and, alternately, makes an electricalconnection between the first top module contact 956 and the secondbottom module contact 967 and, also, between the first bottom modulecontact 957 and the second top module contact 966.

The outlet module 800 (FIGS. 8A-B) and switch module 900 (FIGS. 9A-B)are described above as having top and bottom contacts at the back sideof the back covers 804 (FIG. 8B), 904 (FIG. 9B), with correspondingcontact placement on the wiring panel front side 702 (FIGS. 7A-B). Othercontact placements are contemplated as being within the scope of thepresent invention. For example, one of ordinary skill in the art willrecognize that side contacts along the back side of the back covers orcontacts along the edges or sides of the module covers also would befeasible. Further, the modules 800 (FIGS. 8A-B), 900 (FIGS. 9A-B) aredescribed above as having spring contacts, with corresponding latchesand contact surfaces located on the wiring panel 700 (FIGS. 7A-B). Othercontact types and combinations are contemplated as being within thescope of the present invention. For example, contact surfaces andlatches mounted in the modules 800 (FIGS. 8A-B), 900 (FIGS. 9A-B), withcorresponding spring contacts mounted in the wiring panel 700 (FIGS.7A-B) are also feasible.

Face Plates

FIGS. 10A-D illustrate a face plate 1000, which provides the wall trimfor an installed electrical outlet 310 or switch 360, as described withrespect to FIG. 2, above. As shown in FIGS. 10A-B, one embodiment of aface plate 1000 has a flared-rectangular-shaped cover plate 1010 and acover aperture 1020. In another embodiment, the face plate 1000 has arectangular-shaped cover plate 1080 (FIG. 10C). In yet anotherembodiment, the face plate 1000 has an oval-shaped cover plate 1090(FIG. 11D). The cover plate 1010 has a front side 1012, which is thevisible trim when installed, and a back side 1014, which is not visiblewhen installed flush against a wall. The cover aperture 1020 hasstraight edges and semi-circular ends and fits over the similarly shapedraised portion 810 (FIG. 8A) of an outlet module 800 (FIGS. 8A-B) or thesimilarly shaped rocker switch 910 (FIG. 9A) of a switch module 900(FIGS. 9A-B).

As shown in FIG. 10B, the face plate 1000 is installed onto and removedfrom an installed module 800 (FIGS. 8A-B), 900 (FIGS. 9A-B) without theuse of separate fasteners, such as conventional screws. The plate backside 1014 has protruding tabs 1030, each with an indented portion 1032that latch onto an outlet module catch 803 (FIG. 8D) or switch modulecatch 903 (FIG. 9C). The tabs 1030 releasably retain the face plate 1000when pressed onto an installed outlet module 800 (FIGS. 8A-B) or switchmodule 900 (FIGS. 9A-B). In this manner, the face plate 1000 covers thewall-mounted electrical box 600 (FIGS. 6A-B) and the modules installedtherein.

Protective Cover

FIGS. 11A-B illustrate a protective cover 1100, which protects theinterior of the electrical box 600 (FIGS. 6A-B), the wiring panel 700(FIGS. 7A-B), and the associated power cables installed within theelectrical box 600 (FIGS. 6A-B) during the makeup phase, as describedwith respect to FIG. 14B, below. The protective cover 1100 has a shieldplate 1110, a top sleeve 1120 and a bottom sleeve 1130. The shield plate1110 is generally planar and dimensioned to closely conform to theinterior of the electrical box 600 (FIG. 6A) and the wiring panel frontside 702 (FIG. 7A). The top sleeve 1120 extends perpendicularly from theshield plate 1110 so that the top sleeve inside 1122 fits over the toppanel fixture 710. The bottom sleeve 1130 also extends perpendicularlyfrom the shield plate 1110 so that the bottom sleeve inside 1132 fitsover the bottom panel fixture 720. The shield plate has post slots 1140,cutouts 1150, mounting holes 1160, and a plug opening 1170. The postslots 1140 allow the protective cover 1100 to slide over the modulemounting posts 622 (FIG. 6B) during installation in the electrical box600 (FIGS. 6A-B). The cutouts 1150 and the mounting holes 1160 work inconjunction to allow the protective cover 1100 to be easily secured toand removed from the wiring panel 700 (FIGS. 7A-B) without unfasteningthe wiring panel 700 (FIGS. 7A-B) from the electrical box 600 (FIGS.6A-B), as described with respect to FIG. 12, below. The plug opening1170 allows a standard AC plug to access the wiring panel socket 730when the protective cover is in place, as described with respect to FIG.14B, below.

Protective Cover Installation

FIG. 12 illustrates a protective cover 1100 during installation over awiring panel 700. The protective cover 1100 is installed in the interiorof the electrical box 600 (FIGS. 6A-B) and positioned so as to shieldthe exposed front side 702 of the wiring panel 700, as described withrespect to FIG. 14B, below. The fasteners 707 corresponding to themounting holes 1160 are removed from the wiring panel 700. The fasteners707 corresponding to the cutouts 1150 are not removed duringinstallation or removal of the protective cover 1100, allowing thewiring panel 700 to remain secured inside the electrical box (notshown). As shown in FIG. 12, the protective cover 1100 is positionedwithin the electrical box (not shown) adjacent the wiring panel 700 sothat the protective cover front side 1112 is away from the wiring panelfront side 730 and the protective cover plug opening 1170 aligns withthe wiring panel socket 730. In this position, the protective cover 1100is simply pressed against the wiring panel 700 so that the top panelfixture 710 fits within the top sleeve 1120, the bottom panel fixture720 fits within the bottom sleeve 1130 and the cutouts 150 fit aroundthe remaining fasteners 707. The protective sleeve 1100 then may besecured to the wiring panel 700 with the removed fasteners 707 threadedthrough the protective cover mounting holes 1160, the wiring panelmounting holes 708 (FIG. 7C) and the electrical box panel mounting posts620 (FIGS. 6A-B). Removal of the protective cover 1100 from the wiringpanel 700 prior to module installation simply proceeds in the reverse ofthe above-described steps. The top sleeve 1120 and bottom sleeve 1130provide a gripping surface for removing the protective sleeve 1100.

Box Mount and Electrical Box Installation

FIGS. 13A-C illustrate an electrical box 600 mounted on a box mount 500.The electrical box 600 is typically mounted after the box mount 500 isinstalled on a wall stud, as described with respect to FIG. 14A, below.FIG. 13A illustrates the installation of the electrical box 600 on thebox mount 700 and illustrates the releasable latch 650 within theelectrical box 600 used to lock the electrical box 600 in a fixedposition relative to the box mount 500 and, correspondingly, release theelectrical box 600 so that it can be moved to another fixed position.FIGS. 13B-C illustrate the various fixed positions of the electrical box600.

As shown in FIG. 13A, the electrical box 600 is mounted so that theslides 630 are movably retained within the mounting brackets 530 and theguides 640 are moveable within box mount grooves 540 (FIGS. 6A-B). Thereleasable latch 650 has a tab portion 654 (FIGS. 6A-B) that fits withinbox mount catch slots 560 (FIGS. 13B-C) to lock the electrical box 600at various fixed positions. The latch 650 is released and the electricalbox 600 moved to different positions by inserting a screwdriver tip orsimilar tool into a latch release portion 1310. The screwdriver is thentwisted so that the screwdriver tip pushes the release portion 1310 awayfrom the electrical box wall, temporarily lifting the tab portion 654from a catch slot 560 (FIGS. 13B-C). With the latch 650 released, theelectrical box 600 can be repositioned along the box mount 500 orremoved from the box mount 500 utilizing the finger grip 670 to pull orpush the electrical box 600 along the mounting brackets 530.

As shown in FIGS. 13B-C, the electrical box 600 can be releasably lockedin any one of several fixed positions. Each of these fixed positionslocates the front face 602 a specific distance from the box mountleading edge 502. The box mount 500 is installed on a wall stud, and theleading edge 502 functions as an alignment guide along an edge of thewall stud, as described with respect to FIG. 14A, below. The tab portion654 of the electrical box latch 650 (FIG. 13A), releasably engages anyone of several catch slots 560, which are located at measured positionsalong the box mount 500. In this manner, the electrical box 600 ispositioned so that its open front face 602 is flush with an installedwall panel, advantageously accommodating various wall panel thicknesses.Position indicators 660 align with the leading edge 502 to visiblyindicate the distance from the leading edge 502 to the open face 602associated with the various catch slots 560 and, hence, the variousfixed positions of the electrical box 600.

As shown in FIG. 13B, the electrical box 600 is locked in a firstposition. A particular catch slot 1324 retains the latch tab portion654, and a corresponding position indicator 1322 aligns with the leadingedge 502, visibly indicating 1.25 inches. Thus, the electrical box frontface 602 extends from the box mount leading edge 502 and, hence, a wallstud edge, by 1.25 inches.

As shown in FIG. 13C, the electrical box 600 is locked in a secondposition. A particular catch slot 1334 retains the latch tab portion654, and a corresponding position indicator 1332 aligns with the leadingedge 502, visibly indicating 1.75 inches. Thus, the electrical box frontface 602 extends from the box mount leading edge 502 and, hence, a wallstud, by 1.75 inches. In a particular embodiment, the electrical boxfront face 602 can be extended from the box mount leading edge 502, andhence a wall stud edge, at specific distances in the range of between0.5 inches and 1.75 inches. In another particular embodiment, theelectrical box front-face 602 can be extended from the box mount leadingedge 502, and hence a wall stud edge, at specific distances of 0.5,0.625, 1.25 and 1.75 inches.

The electrical box 600 is described above as having a latch with a tabportion that engages catch slots located along the box mount 500. Othermechanisms for locking the electrical box 600 at various fixed positionsrelative to the box mount 500 are also contemplated as within the scopeof the present invention. For example, the electrical box 600 could havevarious catch slots, with a latch located on the box mount 500. Thecatch slots could be any shaped aperture, which is engaged with acorrespondingly shaped tab portion of the latch.

The box mount 500 is described above as having a leading edge thatfunctions as an alignment guide. Other features of the box mount couldalso function as an alignment guide within the scope of the presentinvention. For example, a feature, such as an arrow or similar indicatorcould be molded or otherwise attached to the box mount and used as analignment guide.

Installation at Rough Framing Phase

FIGS. 14A-B illustrate a mounted electrical box and associatedcomponents installed on a wall stud. FIG. 14A illustrates a partialelectrical box assembly 1400 including a box mount 500 attached to awall stud 1402, a mounted electrical box 600 and an installed wiringpanel 700. FIG. 14B illustrates a shielded partial electrical boxassembly 1460 including a protective cover 1100 installed over thewiring panel 700 (FIG. 14A) of the partial electrical box assembly 1400(FIG. 14A).

As shown in FIG. 14A, the box mount 500 is attached to a wall stud 1402by aligning the box mount leading edge 502 as a guide along the stud'swall-facing edge 1404 and hammering in the fasteners 522, which can bestaples, nails or similar devices. The electrical box 600 is thenattached to the box mount 500, as described with respect to FIG. 13A,above. This alignment in conjunction with the box mount fixed positions560 (FIGS. 13B-C) provides a specific distance from the wall stud to theelectrical box opening 602, allowing the electrical box to be installedflush with a wall panel finished exterior surface, i.e. the surfacetypically painted during the makeup phase, as described with respect toFIGS. 13B-C, above.

Also shown in FIG. 14A is an installed wiring panel 700. The wiringpanel 700 is installed within the electrical box 600 by positioning thewiring panel 700 at the box open front 602 so that the mounting postslots 706 fit over the mounting posts 620. The wiring panel 700 is theninserted into the electrical box 600 until the wiring panel back side704 (FIG. 7B) abuts the panel mounting posts 610 (FIGS. 6A-B). Thewiring panel 700 is secured within the electrical box 600 against thepanel mounting posts 610 (FIGS. 6A-B) by inserting fasteners 707, whichare screws or equivalent devices, through the mounting holes 708 (FIGS.7A-B) and into the panel mounting post centered holes 612 (FIGS. 6A-B).The grips 709 are used to manually grasp and position the wiring panel700 during installation. One grip 709 also allows access to theelectrical box latch 650 (FIG. 13A), for positioning the electrical boxafter installation of the wiring panel 700.

FIG. 14A shows the partial electrical box assembly 1400 as it wouldappear in the rough phase or during replacement of a defective module.The wiring panel 700 partitions the electrical box interior into a useraccessible module compartment 400 between the front face 602 and thewiring panel front side 702 and a user inaccessible wiring compartment(not visible) between the back face 604 (FIG. 6B) and the wiring panelback side 704 (FIG. 7B). The term user accessibility as used herein isunderstood to mean access without removal of the wiring panel 700. Themodule compartment 400 is dimensioned for installation of an outletmodule 800 (FIGS. 5A-B), switch module 900 (FIGS. 9A-B) or similarmodule, such as a dimmer switch. The wiring compartment contains cableconnectors for installation of power cables by a journeyman electrician.

As shown in FIG. 14A, the partitioning of the electrical box interioradvantageously allows access only to the module compartment 400, whichis physically separated from the exposed wiring of the power cableswithin the wiring compartment (not visible). There is no access to thebuilding electrical wiring without physical removal of the wiring panel700, preserving the integrity of the electrical wiring from third-partytampering and protecting third-parties from the shock hazard of exposedhigh voltage conductors. Further, there are no external parts tointerfere with wall panel installation, and there are no exposed cableswithin the module compartment 400 susceptible to fouling or damageduring the makeup building phase. Access to the module compartment,however, which has shielded, snap-in contacts, as described with respectto FIG. 7B, above, allows easy and comparatively safe installation orreplacement of modules by unskilled personnel.

Prior to module installation, which would typically occur after themakeup phase is complete, a socket 730 is available for accepting astandard AC plug, providing electrical power at the construction siteafter verification that the wiring panel 700 is properly wired.Punch-outs or other panel markings (not shown) indicate how the panel700 is wired, such as fall hot, half hot, SPST switch, DPST switch,3-way switch, 4-way switch as described with respect to FIGS. 15-16,below.

As shown in FIG. 14B, the protective cover 1100 shields the interior ofthe electrical box 600 and, in particular, the exposed front side of thewiring panel 700 (FIG. 14A). In this manner, the electrical box 600 andwiring panel 700 (FIG. 14A) are advantageously protected from drywallcompound, paints and other materials used during wall panelinstallation. Prior art wiring assemblies, during this makeup phase,have exposed power cables simply coiled up and pushed into bareelectrical boxes, exposing the wires to fouling and damage from routersused during wall panel installation, as described above. On the otherhand, nothing is exposed to fouling or damage in the partial wiringassembly 1460 of the present invention. After the makeup phase iscomplete, the shield 1100 can be easily removed, as described withrespect to FIG. 12, above. The protective cover 1100 has a plug opening1170 (FIG. 11) corresponding to the wiring panel socket 730 (FIG. 14A),allowing a standard AC plug 1490 to be inserted through the protectivecover 1100 and into the socket 730 (FIG. 14A) for access to electricalpower without removal of the protective cover 1100, e.g. during themakeup phase.

Adapter Wiring Panel

FIG. 15 illustrates an adapter wiring panel 1500, which has a wiringpanel 700 (FIGS. 7A-B) modified with adapter brackets 1510. The adapterbrackets 1510 each have a post 1520, an end piece 1530 and a clip 1540.The post 1520 is fixedly attached to the board 701, extendingperpendicularly away from the front face 702. The end piece 1530 isattached to the end of the post 1520 distal the board 701. The clip 1540is attached to the end piece 1530 perpendicularly to the post 1520.Mounting holes 1532 are provided in each end piece 1530. The adapterwiring panel 1500 is installed within a standard electrical box 100(FIG. 1) with the clips 1540 attached along the top and bottom box edgesand secured with screws 130 (FIG. 1) or equivalent fasteners insertedthrough the mounting holes 1532 and into the mounting posts at the topand bottom of the electrical box 100 (FIG. 1). In this manner, astandard electrical box 100 (FIG. 1) can be converted to a safetyelectrical outlet and switch system that accepts snap-in outlet andswitch modules according to the present invention. Conveniently, theadapter board can be installed in lieu of a wiring panel 700 (FIGS.7A-B) in the electrical box 600 (FIGS. 6A-B) utilizing the clips 1540rather than securing a wiring panel 700 (FIGS. 7A-B) with fasteners 707(FIG. 7C).

The safety electrical outlet and switch system has been disclosed indetail in connection with various embodiments of the present invention.These embodiments are disclosed by way of examples only and are not tolimit the scope of the present invention, which is defined by the claimsthat follow. One of ordinary skill in the art will appreciate manyvariations and modifications within the scope of this invention.

1. An electrical wiring method comprising: installing a wiring panelwithin an electrical box having an open front face, said wiring panelhaving a protective cover to protect said wiring panel from foulingduring wall panel installation or painting, removing said protectivecover from said wiring panel after wall panel installation; andelectrically coupling a module having an electrical function to saidwiring panel.
 2. An electrical wiring module comprising: anon-electrically conductive housing sized to fit within an electricalbox; one or more cable connectors having one or more electrical contactsconfigured to electrically couple with one or more power cables routedto the electrical box; one or more module connectors having one or moreelectrical contacts, the one or more module connectors being configuredto electrically couple to an electrical outlet module that isinstallable at least partially within the electrical box; and one ormore internal conductors electrically coupling the one or moreelectrical contacts of the one or more cable connectors with thecorresponding one or more electrical contacts of the one or more moduleconnectors so as to electrically couple the electrical outlet module tothe one or more power cables when the electrical wiring module and theelectrical outlet module are installed within the box.
 3. The electricalwiring module of claim 2, wherein the one or more module connectors areconfigured to removably couple with the electrical outlet module withoutthe use of tools.
 4. The electrical wiring module of claim 3, whereinthe one or more module connectors comprise plug-in connectors.
 5. Theelectrical wiring module of claim 4, wherein the one or more moduleconnectors are configured to provide positive tactile feedback when amechanical and electrical connection is made between the one or moremodule connectors and the electrical outlet module.
 6. The electricalwiring module of claim 2, wherein the one or more module connectors areconfigured to couple with the electrical outlet module without requiringa user to access exposed portions of the one or more power cables. 7.The electrical wiring module of claim 2, wherein the one or more moduleconnectors are keyed to prevent improper installation of the electricaloutlet module.
 8. The electrical wiring module of claim 2, wherein thewiring module is configured to be secured within the electrical box. 9.The electrical wiring module of claim 8, wherein the wiring module isconfigured to be fixed directly to the electrical box.
 10. Theelectrical wiring module of claim 2, further comprising a protectivecover to protect the one or more module connectors against fouling bybuilding materials.
 11. The electrical wiring module of claim 10,wherein the protective cover prevents installation of the electricaloutlet module without prior removal of the protective cover.
 12. Theelectrical wiring module of claim 11, wherein the protective cover ismounted to the wiring module.
 13. The electrical wiring module of claim12, wherein the protective cover is generally planar and rigid.
 14. Anelectrical distribution method comprising: placing a wiring modulewithin an electrical box that routes an electrical power cable inside abuilding, wherein the wiring module is configured to connect to theelectrical power cable and to distribute electrical power according to afunctional module that is connectable to the wiring module, and whereina protective cover is removably applied to the wiring module; removingthe protective cover from the wiring module after wall panelinstallation around the electrical box; and connecting the functionalmodule to the wiring module.
 15. The electrical distribution method ofclaim 14, wherein the functional module comprises an electrical outletmodule or an electrical switch module.
 16. The electrical distributionmethod of claim 14, wherein connecting the functional module to thewiring module does not require a user to access exposed portions of theelectrical power cable and does not require the use of tools.
 17. Theelectrical distribution method of claim 16, wherein connecting thefunctional module to the wiring module comprises plugging the functionalmodule into the wiring module.
 18. The electrical distribution method ofclaim 17, wherein plugging the functional module into the wiring modulecomprises snapping the functional module into the wiring module.
 19. Theelectrical distribution method of claim 14, further comprising mountingthe functional module to the electrical box.
 20. The electricaldistribution method of claim 14, further comprising mounting the wiringmodule to the electrical box.
 21. The electrical distribution method ofclaim 14, further comprising turning on electrical power to the wiringmodule before installing the functional module.